Paper lamination system



Dec. 1, 1970 G. GERARD 3,544,419

. PAPER LAMINATION SYSTEM Filed Jan. 26, 1968 2 Sheets-Sheet 1 INVENTOR.oeonoe GERARD ATTORNEY Dec. 1; 1970 cs. GERARD PAPER LAMINATION SYSTEM 2Sheets-Sheet 2 Filed Jan. 26, 1968 5 G I F FIG. 7

INVENTOR. GEORGE GERARD Bywfiw ATTORNEY United States Patent US. Cl.161111 8 Claims ABSTRACT OF THE DISCLOSURE The present invention relatesto obtaining a multilayer of laminated paper packaging material in whicha plurality of sheets of a relatively coarse, slightly calendered oruncalendered thin embossed kraft paper are attached together by means ofpiercing and disturbing the fibers of the paper, which causes the fibersof adjacent sheets to interlock under high pressure. This is quitedifferent from embossing, which does not cause an interlocking of fibersof adjacent sheets of paper.

With this pinning or piercing, which causes this interlocking, thesheets may be simultaneously embossed with varying directed patternsextending longitudinally and transversely and also obliquely ordiagonally in respect to the longitudinal axis of the sheet of paper.These sheets are desirably arranged in a series of continuous areas,either triangular, hexagonal or octagonal or preferably squarerectangular, positioned side by side over the entire area of the papersheets. The piercing or interlocking of the fibers may be accomplishedalong the edges of the sheets or at various spaced intervals across thesurface of the sheets and even within the various embossed areas. Theareas are desirably so embossed that in one area will be rows of moundsand recesses parallel with the longitudinal axis of the paper and inadjacent squares or areas will be diagonally arranged rows of mounds andrecesses.

SUMMARY OF THE INVENTION It is among the objects of the presentinvention to provide a novel paper processing system in which aplurality of superimposed sheets of paper may be processed so as toenhance their bulk in volume and then be fixed in a laminated structureto permit ready use thereof for packaging or protective purposes.

Another object is to provide a system of laminating and achieving paperpackaging and protective material through which a plurality of sheets ofpaper or similar matted fibrous materials may be processed at arelatively low cost with minimum manual labor to produce a voluminouslightweight packaging material which can be used widely for wrapping,enclosing or protecting furniture, books, crockery or other objectswhich may be injured or damaged.

A further object is to provide a novel packaging material consisting ofa plurality of superimposed sheets of paper or similar matted fibrousmaterial of light weight yet of great bulk, which will not be subject tolateral displacement or of nesting or lodgment with one another andwhich will adequately protect material subject to scuffing and scoringand particularly furniture, books, crockery and the like.

Still further objects and advantages will appear in the more detaileddescription set forth below, it being understood, however, that thismore detailed description is given by way of illustration andexplanation only and not by way of limitation, since various changestherein may be made by those skilled in the art without departing fromthe scope and spirit of the present invention.

In accomplishing the above objects according to one preferred embodimentof the present invention a plurality Patented Dec. 1, 1970 of sheets oflightweight, porous, slightly calendered or uncalendered paper orsimilar matted materials are fed between matching embossing rolls togive a continuous series of embossments or enlargements and adjacentrecesses which will extend in different directions over the surface ofthe paper so as to prevent nesting thereof.

Desirably the areas of the various directed rows of embossments andrecesses will extend partly in parallelism and transverse to thedirection of movement of the paper and partly obliquely to the directionof movement of the paper, said obliquity being 30 or 60 but preferablyThe embossments generally are provided by impressing the sheets ofmaterial so as to form frusto-conical portions which project bothupwardly and downwardly with rounded ends and with the sides being at anangle to the plane of the paper of between 30 and 60 and desirably at45. The paper sheets after being embossed are then caused to bedisplaced in respect to one another. There may be between two or threeup to fourteen or fifteen paper sheets embossed simultaneously followingwhich the sheets are caused to be offset from one another and then againassembled with a light pressure and then they are pinned or subjected toa pinning operation.

In the pinning operation matching rolls or pins are provided which willcause indentations of the order of less than and desirably of the orderof to with the sharp point of the indentation causing interengagement ofthe superimposed paper sheets.

These indentations may take place at local areas in the middle or at theperiphery of the rows of embossments or mounds and recesses and causethe sheets to be pressed together and firmly engage with one another sothat there will be a direct connection and uniting or integration of thematted fibers of the paper stock. The same effect may be achieved byrunning a pinning roller along the assembled edges of the paper sheetsso as to cause engagement and locking together of the fibers of thesuperimposed paper sheets to achieve a locking elfect.

Desirably the rows of embossments and recesses are arranged in 1" to 3"areas in Width or length which are either square or rectangular andwhich extend over the entire surface of the area of the paper sheets.Each area of longitudinal and transverse embossments is bordered by anarea of diagonal or oblique rows of mounds or embossments.

In the offsetting operation the sheets are desirably olfset by causingthem to press over idler rollers at greater or lesser distances from thedirection paths of travel with the result that the embossments andmounds will be so offset that the mounds of one sheet Will contact thetop of the mounds of the next adjacent sheet without any likelihood ofnesting or coincidence of the various recesses and mounds and withmaximum bulk being achieved.

Desirably the inside faces of these laminated or superimposed sheets maybe provided with sheets of smooth highly calendered kraft paper or withtissue sheets ranging from two to six or more so as to prevent thecoarse, rough basic sheets from abrading or scoring the finish of thefurniture or the cover of the book or causing other damage.

Although varying sizes and shapes and patterns may be employed it hasbeen found most satisfactory to form the areas so that they will eachoccupy 1 to 3" in width and/ or length with the mounds and recesses eachhaving a diameter of about up to the maximum of and desirably between Aand with the spacing of the rows varying in the same amount.

Although the rows in the oblique portions may be at varying angles of30, 45 or they are desirably at 45 and at the junction between the areasthe embossments or recesses will smoothly flow into one another.

At points in or adjacent to the peripheries of the areas 3 or along theedges of the areas there are provided pinnings in which the paper issubjected to pinning tools which will cause engagement of thelaminations with one another and prevent ofisetting thereof once thelaminations have been gathered together.

The mounds and recesses are generally ofiset so that they will not matchor nest and so that the mounds will rest on one another and givesubstantially increased height and thickness to the superimposed sheets.These sheets are used for packing or protecting furniture, books,crockery and the like in shipment, merchandising, handling, storage,etc.

DESCRIPTION OF THE DRAWINGS With the foregoing and other objects inview, the invention consists of the novel construction, combination andarrangement of parts as hereinafter more specifically described, andillustrated in the accompanying drawings, wherein is shown an embodimentof the invention, but it is to be understood that changes, variationsand modifications can be restortedto which fall within the scope of theclaims hereunto appended.

In the drawings wherein like reference characters denote correspondingparts throughout the several views:

FIG. 1 is a side, diagrammatic elevational view illustrating theembossment, offsetting and pinning of the paper sheets.

FIG. 2 is a fragmentary, perspective view of a pinning element.

FIG. 3 is a fragmentary, top plan view partly broken away, of theembossed, pinned paper sheets showing the offsetting thereof.

FIG. 4 is a transverse sectional view upon the line 4-4 of FIG. 3 uponan enlarged scale as compared to FIG. 3.

FIG. 5 is a side perspective view of a pinning roller which may be usedfor achieving continuous pinning efiect along the periphery of thesuperimposed sheets.

FIG. 6 is a fragmentary top plan view of the superimposed sheets partlybroken away to show the under sheets indicating the offsetting thereof.

FIG. 7 is a transverse sectional view upon the line 7-7 of FIG. 6.

FIG. 8 is an enlarged transverse sectional view, showing the effect ofthe interlocking achieved by the piercing or pinning.

DESCRIPTION OF PREFERRED EMBODIMENT Referring to FIG. 1 there is shown aseries of rolls A of paper stock B which may consist of a coarse, roughsurfaced slightly calendered or uncalendered kraft paper or other mattedmaterials. These sheets are then brought together between embossingrolls C which have matching male and female faces and these embossingrolls carry patterns of rows of mounds and recesses arranged at anglesto one another and desirably in areas which may be square or rectangularover the entire surface of the paper.

The embossed sheets D are then passed over the offsetting idler rollersE which will cause the embossments to become offset from one another sothat there will be no likelihood of their nesting or engagement with oneanother and so that maximum bulk may be achieved.

The sheets are then assembled and pressed together between the assemblyrolls F with a pressure of the order of 500 to 3000 pounds per squareinch. This pressure is for the purpose of securing engagement betweenthe rough fiber surface of the engaging or contacting paper sheets.These paper sheets may desirably be of a varying thickness from .01" to.0 with the tissue paper facing sheets or smooth facing sheets havingabout onehalf this thickness. These sheets willthen pass between thepinning rolls G and H and then, if desired, between the marginal pinningelements or structures J and K.

The final superimposed, laminated, embossed and pinned multiple sheet Las shown in FIGS. 3 and 4 will be desirably offset so that the obliquerows M will be over or under diagonal rows N. The pinned portions P maybe centrally located in the areas or be at the borders Q between theareas. As shown in FIG. 4 the pinned areas consist of a series of sharptriangular depressions R with the corners S having their fiberspenetrating adjacent sheets.

In respect to the use of the rollers E, by causing the sheets to traveldifierent distances between the embossing rollers C and the assemblingrollers F, the embossments will be olfset as indicated in FIGS. 3 and 4and a maximum enlargement of the material without increase in weightwill be achieved, as indicated at T in FIG. 4. At the same time, themounds U will contact and rest on one another, leaving the open spaces Vwhich will give a protective action of the superimposed sheets.

In FIGS. 5 to 7 the serrated roller I will form the continuousserrations W along the periphery or margin of the sheets, as shown inFIG. 6 or 7, which will result in permanent engagement and integrationof the sheets along the pinning band W on each side of the packingthickness T. At the same time there will be pinned to the main coarsesheets D, smooth facing sheets X or tissue sheets X, or acombination ofboth, which will prevent scuffing of the furniture or other fragileobjects which may be packaged or enclosed in the combined sheets asshown in FIGS. 4 and 7.

Generally the offsetting is caused to result in a series of contacts asindicated at U in FIGS. 4 and 7 in which the mounds contact each otherat their peaks or along their conical side edges. It has been found thatthese superimposed sheets will give maximum protection to the furnitureor other surfaces which may be covered thereby.

Referring to FIG. 8 there is shown the effect of the pinning or piercingwhich is accomplished by means of the pinning rollers G and H and thepinning wheel J. This causes an actual piercing and disturbance of thefibers of the paper, causing the fibers of one layer to extend into andto look into the surface or fibers of the adjacent layer under highpressure. These pins act to pierce and disturb and cause thispenetration of fibers into adjacent layers and this is not accomplishedby any embossing operation. It will be noted at the apex of the pointsthat the fibers extend into the adjacent layers, causing thisinterlocking effect.

It is thus apparent that the applicant has provided a novel pinned,embossed packing structure which may be utilized for wrapping fragileobjects or the protection of finished faces or in various places whereinsulation 01' protection is desired from a plurality of sheets ofembossed, pinned, coarse paper stock.

While there has been herein described a preferred form of the invention,it should be understood that the same may be altered in details and inrelative arrangement of parts within the scope of the appended claims.

Having now particularly described and ascertained the nature of theinvention, and in what manner the same is to be performed, what isclaimed is:

1. A superimposed laminated embossed multisheet packaging and wrappingmaterial having a longitudinal axis, useful for packaging, wrapping andenclosing furniture, books, crockery and the like, comprising a seriesof superimposed pierced paper sheets, said pierced paper sheets havingfibers extending into one another so that the adjacent sheets will beinterlocked together at the places of piercing, said paper sheets alsohaving a plurality of closely spaced rows of closely spaced superimposednon-nesting embossments, said embossments being formed of longitudinallyand obliquely arranged rows of mounds and recesses arranged inadjuxtaposed areas offset in respect to each other so that the moundswill be in contact with each other at their peaks and whereas thepierced portions are engaged by reason of the interlodgment of thefibers thereof, so as to form a permanent fibrous connection andintegration of said sheets at spaced areas over the width and lengthwithin said adjuxtaposed areas and the contacting mounds being adheredtogether by glue.

2. The wrapping material of claim 1, said pin portions formed bypenetration of the triangular points being positioned in the center ofthe adjuxtaposed areas.

3. The wrapping material of claim 1, in which the paper sheeets are ofrelatively coarse, thin kraft paper.

4. The wrapping material of claim 1, said rows being arranged in areashaving the form of squares or rectangles and each adjacent rectanglehaving the rows arranged in a different direction, one direction beinglongitudinal and lateral of the material and the other being diagonal ofthe material in respect to the longitudinal axis, and said piercedportions being arranged in circular areas at the center of the square orrectangular areas.

5. The wrapping material of claim 1, said adjuxtaposed areas occupyingone inch to three inches in width and length and the mounds and recesseseach having a diameter of about A; inch maximum and inch minimum.

6. The wrapping material of claim 1, the inside faces of said materialhaving a matted fibrous liner of light References Cited UNITED STATESPATENTS 1,771,983 7/1930 Wandel 161-111 2,106,246 1/1938 Fourness161-130 2,200,171 5/1940 Hermanson 161-130 2,288,170 6/1942 Moeller161-130 HAROLD ANSHER, Primary Examiner W.E. HOAG, Assistant ExaminerUS. Cl. X.R.

